Liner hanger

ABSTRACT

Methods and apparatus for radially expanding a tubular member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/483,017, attorney docket no. 25791.61.05, filed on Jan. 6,2004, which is a national stage filing of PCT patent application PCTUS02/20256, filed on Jun. 26, 2002, which claims the benefit of thefiling date of U.S. Provisional Patent Application No. 60/303,740,attorney docket no. 25791.61, filed on Jul. 6, 2001, the disclosures ofwhich are incorporated herein by reference.

This application is also a continuation-in-part of U.S. patentapplication Ser. No. 10/303,992, attorney docket no. 25791.38.07, filedon Nov. 22, 2002, which is a continuation-in-part of the followingpatent applications: (1) U.S. patent application Ser. No. 09/852,026,attorney docket no. 25791.56, filed on May 9, 2001, (now U.S. Pat. No.6,561,227, which issued May 13, 2003), which was a divisionalapplication of U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.3.02, filed on Dec. 3, 1999, (now U.S. Pat. No.6,497,289, which issued Dec. 24, 2002), which claimed the benefit of thefiling date of U.S. Provisional Patent Application No. 60/111,293,attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. patentapplication Ser. No. 09/510,913, attorney docket no. 25791.7.02, filedon Feb. 23, 2000, which claimed the benefit of the filing date of U.S.Provisional Application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S.patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02,filed on Feb. 10, 2000, (now U.S. Pat. No. 6,823,937, which issued Nov.30, 2004), which claimed the benefit of the filing date of U.S.Provisional Application No. 60/119,611, attorney docket no. 25791.8; (4)U.S. patent application Ser. No. 09/969,922, attorney docket no.25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431, whichissued Oct. 21, 2003), which was a continuation of U.S. patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, (now U.S. Pat. No. 6,328,113, which issued Dec. 11,2002), which claimed the benefit of the filing date of U.S. ProvisionalApplication No. 60/108,558, attorney docket no. 25791.9, filed on Nov.16, 1998; (5) U.S. patent application Ser. No. 10/169,434, attorneydocket no. 25791.10.04, filed on Jul. 1, 2002, which claimed the benefitof the filing date of U.S. Provisional Patent Application No.60/183,546, filed on Feb. 18, 2000; (6) U.S. patent application Ser. No.09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,(now U.S. Pat. No. 6,640,903, which issued Nov. 4, 2003), which claimedthe benefit of the filing date of U.S. Provisional Application No.60/124,042, filed on Mar. 11, 1999; (7) U.S. patent application Ser. No.09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000,(now U.S. Pat. No. 6,568,471, which issued May 27, 2003), which claimedthe benefit of the filing dates of U.S. Provisional Application No.60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 andU.S. Provisional Application No. 60/154,047, attorney docket no.25791.29, filed on Sep. 16, 1999; (8) U.S. patent application Ser. No.09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000,(now U.S. Pat. No. 6,575,240, which issued Jun. 10, 2003), which claimedthe benefit of the filing date of U.S. Provisional Patent ApplicationNo. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999;(9) U.S. patent application Ser. No. 09/588,946, attorney docket no.25791.17.02, filed on Jun. 7, 2000, (now U.S. Pat. No. 6,557,640, whichissued May 6, 2003), which claimed the benefit of the filing date ofU.S. Provisional Patent Application No. 60/137,998, attorney docket no.25791.17, filed on Jun. 7, 1999; and (10) U.S. patent application Ser.No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000,(now U.S. Pat. No. 6,604,763, which issued Aug. 12, 2003), which claimedthe benefit of the filing date of U.S. Provisional Application No.60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999.Applicants incorporate by reference the disclosures of theseapplications.

This application is also related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, attorney docket no. 25791.03.02, filedon Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, attorney docket no. 25791.8.02, filedon Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338,attorney docket no. 25791.9.02, filed on Nov. 15, 1999, (5) U.S. patentapplication Ser. No. 09/523,460, attorney docket no. 25791.11.02, filedon Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895,attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patentapplication Ser. No. 09/511,941, attorney docket no. 25791.16.02, filedon Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946,attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patentapplication Ser. No. 09/559,122, attorney docket no. 25791.23.02, filedon Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635,attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S.provisional patent application Ser. No. 60/162,671, attorney docket no.25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, attorney docket no. 25791.29, filed onSep. 16, 1999, (13) U.S. provisional patent application Ser. No.60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14)U.S. provisional patent application Ser. No. 60/159,039, attorney docketno. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patentapplication Ser. No. 60/159,033, attorney docket no. 25791.37, filed onOct. 12, 1999, (16) U.S. provisional patent application Ser. No.60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17)U.S. provisional patent application Ser. No. 60/165,228, attorney docketno. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patentapplication Ser. No. 60/221,443, attorney docket no. 25791.45, filed onJul. 28, 2000, (19) U.S. provisional patent application Ser. No.60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20)U.S. provisional patent application Ser. No. 60/233,638, attorney docketno. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patentapplication Ser. No. 60/237,334, attorney docket no. 25791.48, filed onOct. 2, 2000, (22) U.S. provisional patent application Ser. No.60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001; (23)U.S. provisional patent application Ser. No. 60/262,434, attorney docketno. 25791.51, filed on Jan. 17, 2001; (24) U.S. provisional patentapplication Ser. No. 60/259,486, attorney docket no. 25791.52, filed onJan 3, 2001; and (25) U.S. provisional patent application Ser. No60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, thedisclosures of which are incorporated herein by reference.

This application is related to the following co-pending applications:(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent applicationSer. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3,1999, which claims priority from provisional application 60/111,293,filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913,attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimspriority from provisional application 60/121,702, filed on Feb. 25,1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docketno. 25791.8.02, filed on Feb. 10, 2000, now U.S. Pat. No. 6,823,937which issued Nov. 30, 2004, which claims priority from provisionalapplication 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No.6,328,113, which was filed as U.S. patent application Ser. No.09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999,which claims priority from provisional application 60/108,558, filed onNov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorneydocket no. 25791.10.04, filed on Jul. 1, 2002, which claims priorityfrom provisional application 60/183,546, filed on Feb. 18, 2000, (6)U.S. Pat. No. 6,640,903 which was filed as U.S. patent application Ser.No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000,which claims priority from provisional application 60/124,042, filed onMar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, which claims priority from provisional application60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, whichwas filed as patent application Ser. No. 09/511,941, attorney docket no.25791.16.02, filed on Feb. 24, 2000, which claims priority fromprovisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S.Pat. No. 6,557,640, which was filed as patent application Ser. No.09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,which claims priority from provisional application 60/137,998, filed onJun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorneydocket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-partapplication of U.S. Pat. No. 6,328,113, which was filed as U.S. patentapplication Ser. No. 09/440,338, attorney docket number 25791.9.02,filed on Nov. 15, 1999, which claims priority from provisionalapplication 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No.6,604,763, which was filed as application Ser. No. 09/559,122, attorneydocket no. 25791.23.02, filed on Apr. 26, 2000, which claims priorityfrom provisional application 60/131,106, filed on Apr. 26, 1999, (12)U.S. patent application Ser. No. 10/030,593, attorney docket no.25791.25.08, filed on Jan. 8, 2002, which claims priority fromprovisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S.provisional patent application Ser. No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No.10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002,which claims priority from provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15)U.S. provisional patent application Ser. No. 60/154,047, attorney docketno. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patentapplication Ser. No. 60/438,828, attorney docket no. 25791.31, filed onJan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed asapplication Ser. No. 09/679,907, attorney docket no. 25791.34.02, onOct. 5, 2000, which claims priority from provisional patent applicationSer. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12,1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar.27, 2002, now U.S. Pat. No. 6,695,012 which issued Feb. 24, 2004,attorney docket no. 25791.36.03, which claims priority from provisionalpatent application Ser. No. 60/159,039, attorney docket no. 25791.36,filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,which claims priority from provisional patent application Ser. No.60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20)U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002,attorney docket no. 25791.38.07, which claims priority from provisionalpatent application Ser. No. 60/212,359, attorney docket no. 25791.38,filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser.No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999,(22) U.S. provisional patent application Ser. No. 60/455,051, attorneydocket no. 25791.40, filed on Mar. 14, 2003, (23) PCT applicationUS02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02,which claims priority from U.S. provisional patent application Ser. No.60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24)U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002,attorney docket no. 25791.45.07, which claims priority from provisionalpatent application Ser. No. 60/221,443, attorney docket no. 25791.45,filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/322947,filed on Dec. 18, 2002, attorney docket no. 25791.46.07, which claimspriority from provisional patent application Ser. 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No. 60/262,434, attorney docket no. 25791.51, filed onJan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filedon Jun. 13, 2003, attorney docket no. 25791.52.06, which claims priorityfrom U.S. provisional patent application Ser. No. 60/259,486, attorneydocket no. 25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patentapplication Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docketno. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patentapplication Ser. No. 09/850,093, filed on May 7, 2001, attorney docketno. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289,which was filed as U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.03.02, filed on Dec. 3, 1999, which claims priorityfrom provisional application 60/111,293, filed on Dec. 7, 1998, (33)U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No.09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as adivisional application of U.S. Pat. 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BACKGROUND

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement, a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures may not be drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIG. 1 is a fragmentary cross-sectional illustration of an embodiment ofa liner hanger positioned within a wellbore including a preexistingsection of wellbore casing.

FIG. 2 is a fragmentary cross-sectional illustration of the injection ofa fluidic material into the apparatus of FIG. 2.

FIG. 3 is a fragmentary cross-sectional illustration of the placement ofa ball into the valveable passage of the tubular shoe of the apparatusof FIG. 2.

FIG. 4 is a fragmentary cross-sectional illustration of the continuedinjection of the fluidic material into the apparatus of FIG. 3 in orderto burst the burst discs.

FIG. 5 is a fragmentary cross-sectional illustration of the continuedinjection of the fluidic material into the apparatus of FIG. 4 in orderto plastically deform and radially expand the expandable tubular member.

FIG. 6 is a fragmentary cross-sectional illustration of the completionof the radial expansion and plastic deformation of the expandabletubular member of the apparatus of FIG. 5.

FIG. 7 is a fragmentary cross-sectional illustration of apparatusaccording to one or more aspects of the present disclosure.

FIG. 8 is an enlarged view of a portion of the apparatus of FIG. 7.

FIG. 9 is a fragmentary cross-sectional illustration of the apparatus ofFIG. 7 in an initial or intermediate stage of a tubular member expansionmethod according to one or more aspects of the present disclosure.

FIG. 10 is a fragmentary cross-sectional illustration of the apparatusof FIG. 9 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 11 is a fragmentary cross-sectional illustration of the apparatusof FIG. 10 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 12 is a fragmentary cross-sectional illustration of the apparatusof FIG. 11 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 13 is a fragmentary cross-sectional illustration of the apparatusof FIG. 12 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 14 is a fragmentary cross-sectional illustration of the apparatusof FIG. 13 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 15 is a fragmentary cross-sectional illustration of the apparatusof FIG. 14 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 16 is a fragmentary cross-sectional illustration of the apparatusof FIG. 15 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 17 is a fragmentary cross-sectional illustration of the apparatusof FIG. 16 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 18 is a fragmentary cross-sectional illustration of the apparatusof FIG. 17 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 19 is a fragmentary cross-sectional illustration of the apparatusof FIG. 18 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 20 is a fragmentary cross-sectional illustration of the apparatusof FIG. 19 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 21 is a fragmentary cross-sectional illustration of the apparatusof FIG. 20 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

FIG. 22 is a fragmentary cross-sectional illustration of the apparatusof FIG. 21 in a subsequent stage of the tubular member expansion methodaccording to one or more aspects of the present disclosure.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

An apparatus and method for plastically deforming a tubular liner withina wellbore within a subterranean formation is provided. The apparatusand method thereby provides a system for coupling a radially expandabletubular liner to an open hole or cased section of a wellbore within asubterranean formation. Furthermore, in this manner, a wellbore casing,a pipeline, or a structural support may be formed or repaired using thepresent illustrative embodiments.

Referring initially to FIG. 1, an embodiment of an apparatus 100 forradially expanding and plastically deforming a tubular liner includes atubular support member 105 that defines a passage 105 a that is coupledto a tubular expansion cone 110 that defines a passage 110 a andincludes a recess 110 b for mating with and receiving the tubularsupport member 105, a recess 110 c, and an internal flange 110 d. Thetubular expansion cone 110 further includes a first section 110 e havinga substantially cylindrical outer surface, a second section 110 f havinga substantially tapered conical outer surface, and a third section 110 ghaving a substantially cylindrical outer surface. In an exemplaryembodiment, the outside diameter of the first section 110 e is greaterthan the outside diameter of the third section 110 g. In an exemplaryembodiment, the recess 110 b includes internal threads and the end ofthe tubular support member 105 that is received within the recess 110 bincludes external threads for engaging the internal threads.

An end of a tubular shoe 115 mates with and is movably received withinthe recess 110 c of the tubular expansion cone 110 that defines apassage 115 a and a valveable passage 115 b and includes an externalflange 115 c, and an external flange 115 d including a recessed portion115 da. The tubular shoe 115 further includes radial passages 115 e and115 f for receiving corresponding burst discs, 115 ea and 115 fa. An endof a tubular support member 120 that defines a passage 120 a mates withand is movably received within the recess 115 da of the external flange115 d of the tubular shoe 115 and includes an external flange 120 bhaving a substantially conical outer surface.

An end of an expandable tubular member 125 mates with and is coupled tothe tubular support member 120 that defines a passage 125 a forreceiving the tubular support member 105, the tubular expansion cone110, and the tubular shoe 115. In an exemplary embodiment, the end ofthe expandable tubular member 125 is coupled to the tubular supportmember 120 by a conventional threaded connection. In an exemplaryembodiment, the expandable tubular member 125 includes a first section125 b having a substantially cylindrical outer surface, a second section125 c having a substantially conical outer surface, and a third section125 d having a substantially cylindrical outer surface. In an exemplaryembodiment, the outside diameter of the first section 125 b is greaterthan the outside diameter of the third section 125 d, and a plurality oftubular sealing members, 130 a, 130 b, and 130 c, are coupled to theexternal surface of the first section 125 b of the expandable tubularmember 125.

An end of a tubular member 140 that defines a passage 140 a is coupledto an end of the tubular support member 120. In an exemplary embodiment,the connection between the tubular member 140 and the tubular supportmember 120 is a conventional threaded connection.

In an exemplary embodiment, as illustrated in FIG. 1, the apparatus 100may be positioned within a wellbore 200 within a subterranean formation205 that includes a preexisting section of wellbore casing 210. Thewellbore 200 may be vertical, horizontal, or an intermediateorientation.

As illustrated in FIG. 2, a fluidic material 215 may then be injectedinto the apparatus 100 through the passages 105 a, 110 a, 115 a, 115 b,and 140 a in order to ensure the proper operation of the passages. In analternative embodiment, before or after the injection of the fluidicmaterial 215, a hardenable fluidic sealing material such as, forexample, cement, may be injected into the apparatus 100, through thepassages 105 a, 110 a, 115 a, 115 b, and 140 a, in order to form anannular body of a fluidic sealing material between the tubular member125 and the wellbore 200.

As illustrated in FIG. 3, a ball 220 may then be placed into thevalveable passage 115 b of the tubular shoe 115 by introducing the ballinto the injected fluidic material 215. In this manner, the valveablepassage 115 b of the tubular shoe 115 may be sealed off therebypermitting the passage 115 a to be pressurized by the continuedinjection of the fluidic material 215.

As illustrated in FIG. 4, the continued injection of the fluidicmaterial 215 will burst the burst discs 115 ea and 115 fa therebypermitting the injected fluidic material to pass through the radialpassages 115 e and 115 f into the annular region between the tubularshoe 115 and the expandable tubular member 125 below the tubularexpansion cone 110 above the external flange 115 d of the tubular shoe.

As illustrated in FIG. 5, the continued injection of the fluidicmaterial 215 will continue to pressurize the annular region, between thetubular shoe 115 and the expandable tubular member 125 below the tubularexpansion cone 110 above the external flange 115 d of the tubular shoe,and thereby extrude the expandable tubular member 125 off of the tubularexpansion cone 110 by plastically deforming and radially expanding theexpandable tubular member.

During the continued radial expansion of the expandable tubular member125, the tubular support member 105 and the tubular expansion cone 110may be raised out of the wellbore 200. Because the tubular expansioncone 110 and the tubular shoe 115 are movably coupled, the axialdisplacement of the tubular expansion cone 110 during the radialexpansion of the tubular member 125 does not displace the tubular shoein the axial direction. In an exemplary embodiment, during the radialexpansion and plastic deformation of the expandable tubular member 125,the tubular shoe 120 is supported by the tubular support member 120 inthe axial direction.

In an exemplary embodiment, the radial expansion of the expandabletubular member 125 further causes the sealing members, 130 a, 130 b, and130 c, to engage the preexisting wellbore casing 210. In this manner,the radially expanded tubular member 125, the tubular support member120, and the tubular member 140 are coupled to the preexisting wellborecasing. Furthermore, in this manner, a fluidic seal is provided betweenthe radially expanded tubular member 125 and the preexisting wellborecasing 210.

As illustrated in FIG. 6, once the radial expansion of the expandabletubular member 125 has been completed, the tubular support member 105,the tubular expansion cone 110, and the tubular shoe 115 are removedfrom the wellbore 200. In particular, the external flange 115 c of thetubular shoe 115 engages the internal flange 110 d of the tubularexpansion cone 110 thereby permitting the tubular shoe to be removedfrom the wellbore 200.

In a preferred embodiment, the apparatus 100, and method of operatingthe apparatus, is provided substantially as disclosed in one or more ofthe following: (1) U.S. patent application Ser. No. 09/454,139, attorneydocket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, attorney docket no. 25791.7.02, filedon Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350,attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patentapplication Ser. No. 09/440,338, attorney docket no. 25791.9.02, filedon Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460,attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patentapplication Ser. No. 09/512,895, attorney docket no. 25791.12.02, filedon Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941,attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patentapplication Ser. No. 09/588,946, attorney docket no. 25791.17.02, filedon Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122,attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patentapplication serial No. PCT/US00/18635, attorney docket no. 25791.25.02,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (12)U.S. provisional patent application Ser. No. 60/154,047, attorney docketno. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patentapplication Ser. No. 60/159,082, attorney docket no. 25791.34, filed onOct. 12, 1999, (14) U.S. provisional patent application Ser. No.60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15)U.S. provisional patent application Ser. No. 60/159,033, attorney docketno. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, attorney docket no. 25791.38, filed onJun. 19, 2000, (17) U.S. provisional patent application Ser. No.60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (18)U.S. provisional patent application Ser. No. 60/221,443, attorney docketno. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patentapplication Ser. No. 60/221,645, attorney docket no. 25791.46, filed onJul. 28, 2000, (20) U.S. provisional patent application Ser. No.60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (21)U.S. provisional patent application Ser. No. 60/237,334, attorney docketno. 25791.48, filed on Oct. 2, 2000, (22) U.S. provisional patentapplication Ser. No. 60/270.007, attorney docket no. 25791.50, filed onFeb. 20, 2001; (23) U.S. provisional patent application Ser. No.60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001; (24)U.S. provisional patent application Ser. No. 60/259,486, attorney docketno. 25791.52, filed on Jan. 3, 2001; and (25) U.S. provisional patentapplication Ser. No. 60/303,711, attorney docket no. 25791.44, filed onJul. 6, 2001, the disclosures of which are incorporated herein byreference.

Referring to FIG. 7, illustrated is an embodiment of an apparatus 700for radially expanding and plastically deforming an expandable tubularmember 702 according to one or more aspects of the present disclosure.The apparatus 700 comprises a support member 705 and an expansion device710. The expansion device comprises an anchor 715 and a die 720. Theanchor 715 may also be referred to herein as an anchor portion, a base,or a base portion, and the die 720 may also be referred to herein as adie portion, a former, or a former portion. The apparatus 700 alsoincludes one or more pressure chambers 730, such as a circularannulus-shaped pressure chamber 730 that may be defined between internalsurfaces of the anchor 715 and the die 720. The apparatus 700 alsoincludes one or more biasing elements 735 each comprising one or moresprings or other mechanical biasing elements. Alternatively, oradditionally, the biasing elements 735 may each be hydraulically,magnetically, and/or electrically operable.

The support member 705 is configured to be run down a casing or apartially or wholly cased or uncased wellbore (such casing or wellboreindicated in FIG. 7 by reference number 701) via E-line, slick line,flexible tubing, and/or other means. The support member 705 has ametallic or other rigid construction, and includes a central portion 705a and an annulus-shaped flange portion 705 b located at or near an upperend of the central portion 705 a.

The central portion 705 a may be solid or tubular, and includes aportion 705 aa having a larger outer diameter relative to the remainderof the central portion 705 a. The support member 705 is axiallypositioned relative to the expandable tubular member 702 such that theportion 705 aa extends from the bottom end of the expandable tubularmember 702 to a length 705 ab substantially similar to or greater than acollapsed height 710 a of the expansion device 710. The flange portion705 b has an outer diameter 705 d that is substantially similar to orslightly smaller than an inner diameter or passage 702 a of theexpandable tubular member 702 prior to radial expansion. The centralportion 705 a and the flange portion 705 b may be integrally formed,such as by forging or machining from a single billet of metal roundstock, or they may be discrete components coupled together by welding,press-fitting, mechanical fasteners and/or other means. The outerdiameter of the portion 705 aa of the support member 705 that extendsfrom the bottom of the expandable tubular member 702 may be 0.5″ to 2.0″greater than the outer diameter of the remainder of the central portion705 a of the support member 705. However, other embodiments are alsowithin the scope of the present disclosure.

Detachable coupling means 725 secure the support member 705 to theinside of the expandable tubular member 702. The detachable couplingmeans 725 may be or include one or more packers, tack welds, mechanicalfasteners, mechanical fuses, and/or other means by which the axialposition of the support member 705 may be at least temporarily fixedrelative to the expandable tubular member 702. The detachable couplingmeans 725 may also be configured to allow the support member 705 toslide axially within the expandable tubular member 702 when acted uponby a sufficient axial force.

In an alternative embodiment (not shown in FIG. 7), the central portion705 a of the support member 705 may extend beyond the upper end of theexpandable tubular member 702, and the flange portion 705 b may overlapthe upper end of the expandable tubular member 702, such as where theouter diameter 705 d of the flange portion 705 b is substantiallysimilar to or at least slightly larger than the outer diameter of theexpandable tubular member 702. Nonetheless, the axial position of thesupport member 705 relative to the expandable tubular member 702 maystill be at least temporarily fixed, such as by one or more tack welds,mechanical fasteners, mechanical fuses, and/or other means detachablycoupling the support member 705 to the expandable tubular member 702.

Referring to FIG. 8, illustrated is an enlarged view of a portion of theexpansion device 710 shown in FIG. 7. The expansion device 710 may besubstantially symmetrical, at least with regard to the aspects describedbelow, such that only one half of the cross-sectional view of FIG. 7 isshown in FIG. 8.

The anchor 715 includes a body 805 and an extension 810. The body 805may be substantially disk-shaped except as described herein and depictedin FIG. 8. For example, the body 805 comprises a central apertureconfigured to slidably receive the support member 705 shown in FIG. 7.Several portions of the boundary, perimeter, surface or diameter of thecentral aperture are indicated by reference numeral 820 in FIG. 8. Thebody 805 may also include one or more recesses 825 in the surface 820defined by the central aperture. Each recess 825 may be sized andotherwise configured to receive and possibly retain an o-ring and/orother sealing element 830. Accordingly, fluid flow past the sealingelement 830 between the body 805 and the support member 705 may beprevented.

The extension 810 may be substantially tubular, ring- or annulus-shaped,extending upward from the body 805. The extension 810 may be integrallyformed with the body 805, such as by forging or machining from a singlebillet of metal round stock, or the extension 810 may be a discretecomponent coupled to the body 805 by welding, press-fitting, mechanicalfasteners and/or other means. The extension 810 may have an aspect ratio(height:width) of at least about 2:1, and possibly as great as 10:1,20:1 or more. The height or axial length of the extension 810 may be atleast about 4 inches, and possibly as great as 20 feet or more. Theouter surface or diameter 830 of the extension 810 may be co-cylindricalwith the outer surface or diameter 835 of the body 805. That is, thebody 805 and the extension 810 may be coaxial and have the same outerdiameter. An upper, outside edge of the extension 810 may comprise achamfer 840 and/or otherwise be tapered or rounded.

The extension 810 may include one or more recesses 845 in the innersurface or diameter 850. Each recess 845 may be sized and otherwiseconfigured to receive and possibly retain an o-ring and/or other sealingelement 855. Each recess 845 may be substantially similar to the one ormore recesses 825. Accordingly, fluid flow past the sealing element 855between the extension 810 and an extension 910 of the die 720 may beprevented.

The anchor 715 also includes at least one internal brake 860 and atleast one external brake 865. The internal and external brakes 860, 865may each operate as a function of pressure, such as in response to thepressure within the pressure chamber 730 nearing, exceeding, or fallingbelow a predetermined value. The internal brake 860 is configured toselectively engage the support member 705, such as by selectivelyexerting a radially inward force on the support member 705. The externalbrake 865 is configured to selectively engage the expandable tubularmember 702, such as by selectively exerting a radially outward force onthe expandable tubular member 702. The internal and external brakes 860,865 may each comprise mechanical, hydraulic, magnetic and/or electricalmeans for selectively engaging the support member 702 and/or theexpandable tubular member 702.

In an exemplary embodiment, the internal brake 860 includes a hydraulicpiston 870 fluidicly coupled to the pressure chamber 730, such as viaport 875, and the external brake 865 includes a hydraulic piston 880fluidicly coupled to the pressure chamber 730, such as via port 885. Aninternal shoe or stop 890 is integral or coupled to the piston 870, andis configured to exert a radially inward force on the support member705. An external shoe or stop 895 is integral or coupled to the piston880, and is configured to exert a radially outward force on theexpandable tubular member 702. Springs and/or other biasing means 897 a,897 b may urge the shoes 890, 895 towards disengaged positions, such asthe positions shown in FIG. 8.

The die 720 includes a body 905 and an extension 910. The body 905 maybe substantially disk-shaped except as described herein and depicted inFIG. 8. For example, the body 905 comprises a central apertureconfigured to slidably receive the support member 705 shown in FIG. 7.Several portions of the boundary, perimeter, surface or inner diameterof the central aperture are indicated by reference numeral 920 in FIG.8. The body 905 may include one or more recesses 925 in the surface 920defined by the central aperture. Each recess 925 may be sized andotherwise configured to receive and possibly retain an o-ring and/orother sealing element 930. Accordingly, fluid flow past the sealingelement 930 between the body 905 and the support member 705 may beprevented. An upper, outside edge of the body 905 may comprise a chamfer907 and/or otherwise be tapered or rounded.

The extension 910 may be substantially tubular, ring- or annulus-shaped,extending downward from the body 905. The extension 910 may beintegrally formed with the body 905, such as by forging or machiningfrom a single billet of metal round stock, or the extension 910 may be adiscrete component coupled to the body 905 by welding, press-fitting,mechanical fasteners and/or other means. The extension 910 may have anaspect ratio (height:width) of at least about 2:1, and possibly as greatas 10:1, 20:1 or more. The height or axial length of the extension 910may be at least about 4 inches, and possibly as great as 20 feet ormore. The outer surface or diameter 930 of the extension 910 may besubstantially co-cylindrical with the inner surface or diameter 850 ofthe extension 810 of the anchor 715.

The die 720 also includes at least one internal brake 960 and at leastone external brake 965. The internal and external brakes 960, 965 mayeach operate as a function of pressure, such as in response to thepressure within the pressure chamber 730 nearing, exceeding, or fallingbelow a predetermined value. The internal brake 960 is configured toselectively engage the support member 705, such as by selectivelyexerting a radially inward force on the support member 705. The externalbrake 965 is configured to selectively engage the expandable tubularmember 702, such as by selectively exerting a radially outward force onthe expandable tubular member 702. The internal and external brakes 960,965 may each comprise mechanical, hydraulic, magnetic and/or electricalmeans for selectively engaging the support member 702 and the expandabletubular member 702.

In an exemplary embodiment, the internal brake 960 includes a hydraulicpiston 970 fluidicly coupled to the pressure chamber 730, such as viaport 975, and the external brake 965 includes a hydraulic piston 980fluidicly coupled to the pressure chamber 730, such as via port 985. Aninternal shoe or stop 990 is integral or coupled to the piston 970, andis configured to exert a radially inward force on the support member705. An external shoe or stop 995 is integral or coupled to the piston980, and is configured to exert a radially outward force on theexpandable tubular member 702. Springs and/or other biasing means 997 a,997 b may urge the shoes 990, 995 towards engaged positions, such as thepositions shown in FIG. 8.

In operation, the internal and external brakes 860, 865 of the anchor715 may have a default position when the pressure in the chamber 730 isa nominal pressure or is otherwise below a predetermined pressure levelhereafter referred to as an expansion pressure. This default positionmay be a disengaged position in which the internal brake 860 does notengage the support member 705 and the external brake 865 does not engagethe expandable tubular member 702 (such as the position depicted in FIG.8). Moreover, when the pressure in the chamber 730 is below theexpansion pressure, the internal and external brakes 960, 965 of the die720 may have a default position (such as the position depicted in FIG.8). This default position may be an engaged position in which theinternal brake 960 engages the support member 705 and/or the externalbrake 965 engages the expandable tubular member 702 (such as theposition depicted in FIG. 8).

As the pressure in the chamber 730 increases, the internal and externalbrakes 860, 865 of the anchor may move away from their disengagedpositions and towards an engaged portion. That is, pressure in thechamber 730 may be increased by directing hydraulic fluid flow into thechamber 730, such as through an opening in the support member 705fluidicly coupling the inside of the support member 705 with the chamber730, among other means. The increased pressure operates to urge thepiston 870 inward towards an engaged position, overcoming the outwardforce of the spring 897 a. Similarly, the increased pressure operates tourge the piston 880 outward towards an engaged position, overcoming theinward force of the spring 897 b. Simultaneously, the increased pressureoperates to urge the piston 970 outward towards a disengaged position,overcoming the inward force of the spring 997 a, and also operates tourge the piston 980 inward towards a disengaged position, overcoming theoutward force of the spring 997 b.

As the pressure in the chamber 730 continues to increase, the shoes 890,895 engage the support member 705 and/or the expandable tubular member702, and the shoes 990, 995 disengage the support member 705 and/or theexpandable tubular member 702. With further increase in pressure, thesize of the chamber 730 increases as the die 720 translates axiallyupward and away from the anchor 715.

Once the chamber 730 is expanded to a desired size by translating thedie 720 away from the anchor 715, depressurization of the chamber 730may be initiated, such as by allowing hydraulic fluid to flow out of thechamber 730, possibly into the support member 705. As the pressure inthe chamber 730 decreases toward and below the expansion pressure, thepiston 870 is again urged outward towards a disengaged position as theoutward force of the spring 897 a overcomes the inward force of pressureacting on the piston 870. Similarly, the piston 880 is again urgedinward towards a disengaged position as the inward force of the spring897 b overcomes the outward force of pressure acting on the piston 880.Simultaneously, the decreased pressure allows the piston 970 to again beurged inward towards an engaged position as the inward force of thespring 997 a overcomes the outward force of pressure acting on thepiston 970, and also allows the piston 980 to again be urged outwardtowards an engaged position as the outward force of the spring 997 bovercomes the inward force of pressure acting on the piston 980.

Consequently, as the pressure in the chamber 730 continues to decrease,the shoes 890, 895 disengage the support member 705 and/or theexpandable tubular member 702, and the shoes 990, 995 engage the supportmember 705 and/or the expandable tubular member 702. With furtherdecrease in pressure, the size of the chamber 730 decreases as theanchor 715 translates axially upward and towards the die 720 in responseto the tensile force of the biasing means 735. This process may berepeated any number of times to expand incremental portions of theexpandable tubular member 702, as described below with reference toFIGS. 9-22.

Referring to FIG. 9, illustrated is a sectional view of the apparatus700 shown in FIGS. 7 and 8 in an initial or intermediate stage ofoperation. The pressure inside the chamber 730 of the expansion device710 is just below the expansion pressure, such that the expansion device710 remains collapsed yet the internal brakes 860 of the anchor 715 areengaged with the thicker portion 705 aa of the support member 705 andthe internal brakes 960 of the die 720 are disengaged from the supportmember 705. The expandable tubular member 702 is in a pre-expanded stateand is positioned at or near the chamfer 907 of the die 720.

Referring to FIG. 10, illustrated is a sectional view of the apparatus700 shown in FIG. 9 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increasedbeyond the expansion pressure, such that the expansion device 710 hasexpanded while the internal brakes 860 of the anchor 715 remain engagedwith the thicker portion 705 aa of the support member 705 and theinternal brakes 960 of the die 720 remain disengaged from the supportmember 705. As a result of the expansion of the expansion device 710,the die 720 has been forced into the end of the expandable tubularmember 702, thereby radially expanding and plastically deforming aportion 702 b of the expandable tubular member 702 to a diameter atleast as large as the outer diameter of the die 720. The expansion ofthe expansion device 710 includes the axial translation of the die 720along the support member 705 a distance sufficient for the internalbrakes 960 of the die 720 to travel past the thicker portion 705 aa ofthe support member 705 and for the external brakes 965 of the die 720 totravel into the expanded portion 702 b of the expandable tubular member702.

Referring to FIG. 11, illustrated is a sectional view of the apparatus700 shown in FIG. 10 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been decreased tojust below the expansion pressure, such that the external brakes 965 ofthe die 720 have engaged the internal surface of the expanded portion702 b of the expandable tubular member 702, and such that the internalbrakes 860 of the anchor 715 have disengaged from the thicker portion705 aa of the support member 705.

Referring to FIG. 12, illustrated is a sectional view of the apparatus700 shown in FIG. 11 in a subsequent stage of operation. As the pressureinside the chamber 730 of the expansion device 710 continues to decreasefurther below the expansion pressure, the biasing means 735 begin toovercome the pressure inside the chamber 730 and draw the anchor 715upwards towards the die 720, possibly ultimately to the collapsedconfiguration shown in FIG. 12.

Referring to FIG. 13, illustrated is a sectional view of the apparatus700 shown in FIG. 12 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increased tojust below the expansion pressure, such that the expansion device 710remains collapsed yet the internal brakes 860 of the anchor 715 onceagain engage the thicker portion 705 aa of the support member 705 andthe external brakes 965 of the die 720 disengage from the expandedportion 702 b of the expandable tubular member 702.

Referring to FIG. 14, illustrated is a sectional view of the apparatus700 shown in FIG. 13 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increasedbeyond the expansion pressure, such that the expansion device 710 hasexpanded while the internal brakes 860 of the anchor 715 remain engagedwith the thicker portion 705 aa of the support member 705 and theexternal brakes 965 of the die 720 remain disengaged from the expandedportion 702 b of the expandable tubular member 702. As a result of theexpansion of the expansion device 710, the die 720 has been forcedfurther into the expandable tubular member 702, thereby increasing theportion 702 b of the expandable tubular member 702 that has beenradially expanded and plastically deformed. The lower end of theexpanded portion 702 b also now interposes the outer diameter of theanchor 715 and the wellbore or casing 701.

Referring to FIG. 15, illustrated is a sectional view of the apparatus700 shown in FIG. 14 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been decreased tojust below the expansion pressure, such that the external brakes 965 ofthe die 720 have once again engaged the internal surface of the expandedportion 702 b of the expandable tubular member 702, and such that theinternal brakes 860 of the anchor 715 have disengaged from the thickerportion 705 aa of the support member 705.

Referring to FIG. 16, illustrated is a sectional view of the apparatus700 shown in FIG. 15 in a subsequent stage of operation. As the pressureinside the chamber 730 of the expansion device 710 continues to decreasefurther below the expansion pressure, the biasing means 735 begin toovercome the pressure inside the chamber 730 and draw the anchor 715upwards towards the die 720, possibly ultimately to the collapsedconfiguration shown in FIG. 16.

Referring to FIG. 17, illustrated is a sectional view of the apparatus700 shown in FIG. 16 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increased tojust below the expansion pressure, such that the expansion device 710remains collapsed yet the internal brakes 860 of the anchor 715 onceagain engage the thicker portion 705 aa of the support member 705 andthe external brakes 965 of the die 720 disengage from the expandedportion 702 b of the expandable tubular member 702.

Referring to FIG. 18, illustrated is a sectional view of the apparatus700 shown in FIG. 17 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increasedbeyond the expansion pressure, such that the expansion device 710 hasexpanded while the internal brakes 860 of the anchor 715 remain engagedwith the thicker portion 705 aa of the support member 705 and theexternal brakes 965 of the die 720 remain disengaged from the expandedportion 702 b of the expandable tubular member 702. As a result of theexpansion of the expansion device 710, the die 720 has been forcedfurther into the expandable tubular member 702, thereby increasing theportion 702 b of the expandable tubular member 702 that has beenradially expanded and plastically deformed.

Referring to FIG. 19, illustrated is a sectional view of the apparatus700 shown in FIG. 18 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been decreased tojust below the expansion pressure, such that the external brakes 965 ofthe die 720 have once again engaged the internal surface of the expandedportion 702 b of the expandable tubular member 702, and such that theinternal brakes 860 of the anchor 715 have disengaged from the thickerportion 705 aa of the support member 705.

Referring to FIG. 20, illustrated is a sectional view of the apparatus700 shown in FIG. 19 in a subsequent stage of operation. As the pressureinside the chamber 730 of the expansion device 710 continues to decreasefurther below the expansion pressure, the biasing means 735 begin toovercome the pressure inside the chamber 730 and draw the anchor 715upwards towards the die 720, possibly ultimately to the collapsedconfiguration shown in FIG. 20. The expanded portion 702 b of theexpandable tubular member 702 now extends between the outer brakes 865of the anchor 715 and the wellbore or casing 701. Also, the contractionof the expansion device 710 includes the axial translation of the anchor715 along the support member 705 a distance sufficient for the internalbrakes 860 of the anchor 715 to travel upward past the thicker portion705 aa of the support member 705, and for the external brakes 865 of theanchor 715 to travel into the end of the expanded portion 702 b of theexpandable tubular member 702 such that the expanded portion 702 b ofthe expandable tubular member 702 interposes the external brakes 865 ofthe anchor 715 and the wellbore or casing 701.

Referring to FIG. 21, illustrated is a sectional view of the apparatus700 shown in FIG. 20 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increased tojust below the expansion pressure, such that the expansion device 710remains collapsed yet the external brakes 865 of the anchor 715 engagethe expanded portion 702 b of the expandable tubular member 702 and theexternal brakes 965 of the die 720 disengage from the expanded portion702 b of the expandable tubular member 702.

Referring to FIG. 22, illustrated is a sectional view of the apparatus700 shown in FIG. 21 in a subsequent stage of operation. The pressureinside the chamber 730 of the expansion device 710 has been increasedbeyond the expansion pressure, such that the expansion device 710 hasexpanded while the external brakes 865 of the anchor 715 remain engagedwith the expanded portion 702 b of the expandable tubular member 702 andthe external brakes 965 of the die 720 remain disengaged from theexpanded portion 702 b of the expandable tubular member 702. As a resultof the expansion of the expansion device 710, the die 720 has beenforced further into the expandable tubular member 702, therebyincreasing the portion 702 b of the expandable tubular member 702 thathas been radially expanded and plastically deformed.

The incremental or “inchworm” process shown in FIGS. 9-22 may becontinued until the desired length of the expandable tubular member 702has been radially expanded and plastically deformed. In an exemplaryembodiment, the detachable coupling means 725 may be configured to allowthe support member 705 to ride upwards resting on the expansion device710. Thereafter, the support member 705 may be removed by any of myriadmeans. Alternatively, the support member 705 may be removed once theexpansion device 710 has traveled past the thicker portion 705 aa of thesupport member 705.

In an exemplary embodiment, the incremental process depicted in FIGS.9-22 may be employed as a method of radially expanding the expandabletubular member 702 with the expansion device 710 having a base 715 thatis movable relative to the expandable tubular member 702, a former 720that is movable relative to the expandable tubular member 702 and thebase 715, and a pressure chamber 730 interposing the base 715 and theformer 720. Such a method may comprise sensing a first pressure withinthe pressure chamber 730 via each of a first pressure sensing element ofthe base 715 and a second pressure sensing element of the former 720.For example, the first pressure sensing element may comprise or beassociated with the piston 870/spring 897 a configuration and/or thepiston 870/spring 897 b configuration shown in FIG. 8, and the secondpressure sensing element may comprise or be associated with the piston970/spring 997 a configuration and/or the piston 980/spring 997 bconfiguration shown in FIG. 8. The method may further comprisepositionally fixing the base 715 relative to the expandable tubularmember 702 in response to the first pressure sensing element of the base715 sensing that the first pressure in the pressure chamber 730 exceedsa first predetermined pressure. The method may further comprisepositionally releasing the former 720 relative to the expandable tubularmember 702 in response to the second pressure sensing element of theformer 720 sensing that the first pressure exceeds the firstpredetermined pressure. The method may further comprise sensing a secondpressure within the pressure chamber 730 via a third pressure sensingelement of at least one of the base 715 and the former 720. For example,the third pressure sensing element may comprise or be associated withthe biasing means 735 shown in FIG. 8. The method may further comprisedisplacing the former 720 away from the base 715 and through theexpandable tubular member 702 in response to the third pressure sensingelement sensing that the second pressure exceeds a second predeterminedpressure.

Referring to FIG. 23, illustrated is a sectional view of an embodimentof the apparatus 700 shown in FIGS. 7-22, herein designated by referencenumeral 700 a. The apparatus 700 a is substantially identical to theapparatus 700 shown in FIGS. 7-22. However, the apparatus 700 a isdepicted as further comprising a hydraulic system 1000 coupled to thebase 715. Of course, in an exemplary embodiment, the apparatus 700 shownin FIGS. 7-22 also includes the hydraulic system 1000 shown in FIG. 23.Nonetheless, for the sake of clarity, and because the hydraulic system1000 is but one example of means for operating the apparatus 700 shownin FIGS. 7-22, the hydraulic system 1000 is not shown in FIGS. 7-22.

The hydraulic system 1000 comprises a hydraulic reservoir 1010 and ahydraulic pump 1020. The hydraulic reservoir 1010 is an annulus shapedreservoir extending around the support member 705 and configured tocontain hydraulic fluid, possibly under pressure. The hydraulicreservoir 1010 is coupled to the base 715, whether directly orindirectly, by threaded or other mechanical fasteners, welding and/orother coupling means.

The hydraulic pump 1020 is fluidicly coupled between the hydraulicreservoir 1010 and a passage 1030 leading to the pressure chamber 730.The hydraulic pump 1020, which may be a conventional or future-developedpump, is configured to transmit hydraulic fluid from the hydraulicreservoir 1010 to the pressure chamber 730 via the passage 1030 topressurize the pressure chamber 730 and thereby provide the expansionforce necessary to overcome the biasing means 735 and transition theformer 720 away from the base 715. The hydraulic pump 1020 is alsoconfigured to transmit hydraulic fluid from the pressure chamber 730 viathe passage 1030 to the hydraulic reservoir 1010 to depressurize thepressure chamber 730 and thereby allow the biasing means 735 to draw thebase 715 and the former 720 back together. In an alternative embodiment,the hydraulic pump 1020 may comprise, or be replaced by, two or moreseparate pumps, including one or more pumps for transmitting hydraulicfluid from the hydraulic reservoir 1010 to the pressure chamber 730, andanother one or more pumps for transmitting hydraulic fluid from thepressure chamber 730 to the hydraulic reservoir 1010.

The hydraulic system 1000 may be remotely operated, whether wirelesslyor via an electronic or hydraulic communication umbilical 1040 extendingaway from the hydraulic pump 1020 and/or other component of thehydraulic system 1000 to a controller and/or operator located remotefrom the apparatus 700. For example, in an exemplary embodiment in whichthe apparatus 700 is utilized to install or repair a section of awellbore casing, the communication umbilical 1040 may extend up theborehole to a control module or operator located at the surface. Inanother exemplary embodiment, in which the apparatus 700 is utilized torepair a section of a pipeline, the communication umbilical 1040 mayextend inside the pipeline to an opening in the pipeline where repairpersonnel are positioned to remotely operate the apparatus 700.Consequently, the apparatus 700 may be remotely operated from a distanceof several thousand feet, or more. The communication umbilical 1040 mayextend through a portion of the hydraulic reservoir 1010, as shown inFIG. 23, or along the outside of the hydraulic reservoir 1010, orotherwise.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the apparatus100 and/or the apparatus 700 may be used to form and/or repair, forexample, a wellbore casing, a pipeline, or a structural support.Furthermore, the burst discs 115 ea and 115 fa of the apparatus 100 maybe replaced with conventional pressure relief valves.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. A method of radially expanding a tubular member, comprising: couplingan expansion assembly to the tubular member, wherein the expansionassembly comprises a support member, an anchor and a die, wherein thesupport member extends through the anchor and the die, and wherein thesupport member is coupled to the tubular member; restricting movement ofthe anchor relative to the tubular and support members while displacingthe die through the tubular member to radially expand the tubularmember; and restricting movement of the die relative to the tubular andsupport members while displacing the anchor through the tubular member.2. The method of claim 1 wherein the anchor comprises a brake configuredto selectively engage the support member, and wherein coupling theexpansion assembly to the support member comprises engaging the supportmember with the brake.
 3. The method of claim 1 wherein the anchorcomprises a first brake configured to selectively engage the supportmember and a second brake configured to selectively engage the tubularmember, and wherein restricting movement of the anchor relative to thesupport member comprises at least one of: engaging the support memberwith the first brake; and engaging the tubular member with the secondbrake.
 4. The method of claim 1 wherein the die comprises a first brakeconfigured to selectively engage the support member and a second brakeconfigured to selectively engage the tubular member, and whereindisplacing the die through the tubular member comprises disengaging thefirst brake from the support member and disengaging the second brakefrom the tubular member.
 5. The method of claim 1 wherein the diecomprises a first brake configured to selectively engage the supportmember and a second brake configured to selectively engage the tubularmember, and wherein restricting movement of the die relative to thesupport member comprises at least one of: engaging the support memberwith the first brake; and engaging the tubular member with the secondbrake.
 6. The method of claim 1 wherein the anchor comprises a firstbrake configured to selectively engage the support member and a secondbrake configured to selectively engage the tubular member, and whereindisplacing the anchor through the tubular member comprises disengagingthe first brake from the support member and disengaging the second brakefrom the tubular member.
 7. The method of claim 1 wherein: the anchorcomprises a first brake configured to selectively engage the supportmember and a second brake configured to selectively engage the tubularmember; the die comprises a third brake configured to selectively engagethe support member and a fourth brake configured to selective engage thetubular member; restricting movement of the anchor relative to thesupport member while displacing the die through the tubular member toradially expand the tubular member comprises: engaging one of thesupport member and the tubular member with one of the first and secondbrakes; disengaging the third brake from the support member; anddisengaging the fourth brake from the tubular member; and restrictingmovement of the die relative to the support member while displacing theanchor through the tubular member comprises: disengaging the first brakefrom the support member; disengaging the second brake from the tubularmember; and engaging one of the support member and the tubular memberwith one of the third and fourth brakes.
 8. The method of claim 1wherein the expansion assembly comprises a pressure chamber defined byinternal surfaces of the anchor and the die and an external surface ofthe support member, wherein displacing the anchor through the tubularmember comprises pressurizing the pressure chamber, and whereindisplacing the anchor through the tubular member comprisesdepressurizing the pressure chamber.
 9. The method of claim 8 whereinthe expansion assembly comprises a reservoir coupled to the anchor and apump fluidicly coupled between the reservoir and the pressure chamber,wherein pressurizing the pressure chamber comprises operating the pumpto transmit hydraulic fluid from the reservoir to the pressure chamber,and wherein depressurizing the pressure chamber comprises operating thepump to transmit hydraulic fluid from the pressure chamber to thereservoir.
 10. A system for radially expanding a tubular member with anexpansion assembly comprising a support member, an anchor and a die,wherein the support member extends through the anchor and the die, andwherein the support member is coupled to the tubular member, the systemcomprising: means for restricting movement of the anchor relative to thetubular and support members while displacing the die through the tubularmember to radially expand the tubular member; and means for restrictingmovement of the die relative to the tubular and support members whiledisplacing the anchor through the tubular member.
 11. The system ofclaim 10 wherein the anchor comprises means for selectively engaging thesupport member and means for selectively engaging the tubular member.12. The system of claim 11 wherein the die comprises means forselectively engaging the support member and means for selectivelyengaging the tubular member.
 13. The system of claim 10 wherein the diecomprises means for selectively engaging the support member and meansfor selectively engaging the tubular member.
 14. The system of claim 10wherein the expansion assembly comprises a pressure chamber defined byinternal surfaces of the anchor and the die and an external surface ofthe support member, and wherein the system further comprises means forpressurizing and depressurizing the pressure chamber.
 15. A method ofoperating an expansion device having a support member, a base that ismovable relative to the support member and that comprises a firstpressure sensing element, a former that is movable relative to thesupport member and the base and that comprises a second pressure sensingelement, and a pressure chamber interposing the base and the former, themethod comprising: sensing a first pressure within the pressure chambervia the first pressure sensing element; positionally fixing the baserelative to the support member as a function of the first pressuresensed by the first pressure sensing element; sensing a second pressurewithin the pressure chamber via the second pressure sensing element;positionally releasing the former relative to the support member as afunction of the second pressure sensed by the second pressure sensingelement; sensing a third pressure within the pressure chamber via athird pressure sensing element of at least one of the base and theformer; and displacing the former away from the base as a function ofthe third pressure sensed by the third pressure sensing element.
 16. Themethod of claim 15 wherein the former comprises a brake configured toselectively engage the support member, and wherein positionally fixingthe base relative to the support member comprises engaging the supportmember with the first brake.
 17. The method of claim 15 wherein theformer comprises a brake configured to selectively engage the supportmember, and wherein positionally releasing the former relative to thesupport member comprises disengaging the brake from the support member.18. The method of claim 15 wherein the base comprises a first brakeconfigured to selectively engage the support member, wherein the formercomprises a second brake configured to selectively engage the supportmember, and wherein displacing the former away from the base comprisesengaging the support member with the first brake and disengaging thesecond brake from the support member.
 19. The method of claim 15 whereinthe pressure chamber is defined by internal surfaces of the base and theformer and an external surface of the support member, and whereindisplacing the former away from the base comprises pressurizing thepressure chamber.
 20. The method of claim 19 wherein the expansionassembly comprises a reservoir coupled to the base and a pump fluidiclycoupled between the reservoir and the pressure chamber, and whereinpressurizing the pressure chamber comprises operating the pump totransmit hydraulic fluid from the reservoir to the pressure chamber. 21.The method of claim 15 further comprising: sensing a fourth pressurewithin the pressure chamber via the first pressure sensing element;positionally releasing the base relative to the support member as afunction of the fourth pressure sensed by the first pressure sensingelement; sensing a fifth pressure within the pressure chamber via thesecond pressure sensing element; positionally fixing the former relativeto the support member as a function of the fifth pressure sensed by thesecond pressure sensing element; sensing a sixth pressure within thepressure chamber via the third pressure sensing element; and displacingthe base towards the former as a function of the sixth pressure sensedby the third pressure sensing element.
 22. The method of claim 21wherein the base comprises a brake configured to selectively engage thesupport member, and wherein positionally releasing the base relative tothe support member comprises disengaging the brake from the supportmember.
 23. The method of claim 21 wherein the former comprises a brakeconfigured to selectively engage the support member, and whereinpositionally fixing the former relative to the support member comprisesengaging the support member with the brake.
 24. The method of claim 21wherein the base comprises a first brake configured to selectivelyengage the support member, wherein the former comprises a second brakeconfigured to selectively engage the support member, and whereindisplacing the base towards from the former comprises disengaging thefirst brake from the support member and engaging the support member withthe second brake.
 25. The method of claim 21 wherein the pressurechamber is defined by internal surfaces of the base and the former andan external surface of the support member, wherein displacing the formeraway from the base comprises pressurizing the pressure chamber, andwherein displacing the base towards the former comprises depressurizingthe pressure chamber.
 26. The method of claim 25 wherein the expansionassembly comprises a reservoir coupled to the base and a pump fluidiclycoupled between the reservoir and the pressure chamber, whereinpressurizing the pressure chamber comprises operating the pump totransmit hydraulic fluid from the reservoir to the pressure chamber, andwherein depressurizing the pressure chamber comprises operating the pumpto transmit hydraulic fluid from the pressure chamber to the reservoir.27. A system for operating an expansion device having a support member,a base that is movable relative to the support member, a former that ismovable relative to the support member and the base, and a pressurechamber interposing the base and the former, the system comprising:means for sensing a first pressure within the pressure chamber; meansfor positionally fixing the base relative to the support member as afunction of the first pressure; means for sensing a second pressurewithin the pressure chamber; means for positionally releasing the formerrelative to the support member as a function of the second pressure;means for sensing a third pressure within the pressure chamber; andmeans for displacing the former away from the base as a function of thethird pressure.
 28. The system of claim 27 wherein the base comprisesmeans for selectively engaging the support member, and wherein the meansfor selectively engaging the support member and the means forpositionally fixing the base relative to the support member areconfigured to cooperate to engage the support member.
 29. The system ofclaim 27 wherein the former comprises means for selectively engaging thesupport member, and wherein the means for selectively engaging thesupport member and the means for positionally releasing the formerrelative to the support member are configured to cooperate to disengagethe support member.
 30. The system of claim 27 wherein the basecomprises means for selectively engaging the support member that areconfigured to cooperate with the means for displacing the former awayfrom the base to engage the support member, and wherein the formercomprises means for selectively engaging the support member that areconfigured to cooperate with the means for displacing the former awayfrom the base to disengage the support member.
 31. The system of claim27 wherein the pressure chamber is defined by internal surfaces of thebase and the former and an external surface of the support member, andwherein the means for displacing the former away from the base comprisesmeans for pressurizing the pressure chamber.
 32. The system of claim 31wherein the expansion assembly comprises a reservoir coupled to thebase, and wherein the means for pressurizing the pressure chambercomprises means for transmitting hydraulic fluid from the reservoir tothe pressure chamber.
 33. The system of claim 27 further comprising:means for sensing a fourth pressure within the pressure chamber; meansfor positionally releasing the base relative to the support member as afunction of the fourth pressure; means for sensing a fifth pressurewithin the pressure chamber; means for positionally fixing the formerrelative to the support member as a function of the fifth pressure;means for sensing a sixth pressure within the pressure chamber; andmeans for displacing the base towards the former as a function of thesixth pressure.
 34. The system of claim 33 wherein the base comprisesmeans for selectively engaging the support member, and wherein the meansfor selectively engaging the support member and the means forpositionally releasing the base relative to the support member areconfigured to cooperate to disengage the support member.
 35. The systemof claim 33 wherein the former comprises means for selectively engagingthe support member, and wherein the means for selectively engaging thesupport member and the means for positionally fixing the former relativeto the support member are configured to cooperate to engage the supportmember.
 36. The system of claim 33 wherein the base comprises means forselectively engaging the support member that are configured to cooperatewith the means for displacing the base towards the former to disengagethe support member, and wherein the former comprises means forselectively engaging the support member that are configured to cooperatewith the means for displacing the base towards from the former to engagethe support member
 37. The system of claim 33 wherein the pressurechamber is defined by internal surfaces of the base and the former andan external surface of the support member, wherein the means fordisplacing the former away from the base comprises means forpressurizing the pressure chamber, and wherein the means for displacingthe base towards the former comprises means for depressurizing thepressure chamber.
 38. The system of claim 37 wherein the expansionassembly comprises a reservoir coupled to the base, wherein the meansfor pressurizing the pressure chamber comprises means for transmittinghydraulic fluid from the reservoir to the pressure chamber, and whereinthe means for depressurizing the pressure chamber comprises means fortransmitting hydraulic fluid from the pressure chamber to the reservoir.39. An apparatus for radially expanding a tubular member, comprising: asupport member configured to couple to the tubular member; and anexpansion device movably coupled to the support member and comprising:an expansion surface adapted to be displaced in the longitudinaldirection relative to the support member for radially expanding andplastically deforming the expandable tubular member; and one or morepressure sensing elements operably coupled to the expansion surface forcontrolling the longitudinal displacement of the expansion surfacewithin the expandable tubular member as a function of sensed operatingpressure.
 40. The apparatus of claim 39 wherein the support membercomprises a flange portion and a tubular portion, wherein the flangeportion is coupled to the tubular member, and wherein the tubularportion extends within the tubular member.
 41. The apparatus of claim 40wherein the expansion device includes a central passage through whichthe tubular portion of the support member extends.
 42. The apparatus ofclaim 41 wherein the expansion device comprises an anchor, a die, and apressure chamber, wherein the die comprises the expansion surface,wherein the pressure chamber is defined by internal surfaces of theanchor and the die and an external surface of the support member, andwherein the one or more pressure sensing elements are hydraulicallycoupled to the pressure chamber.
 43. The apparatus of claim 42 whereinthe anchor and the die each comprise an independently operable internalbrake configured to selectively engage the support member.
 44. Theapparatus of claim 43 wherein the internal brakes of the anchor and thedie are configured to selectively engage the support member as afunction of sensed operating pressure within the pressure chamber. 45.The apparatus of claim 42 wherein the anchor and the die each comprisean independently operable external brake configured to selectivelyengage the tubular member.
 46. The apparatus of claim 45 wherein theexternal brakes of the anchor and the die are configured to selectivelyengage the tubular member as a function of sensed operating pressurewithin the pressure chamber.
 47. The apparatus of claim 46 wherein: at afirst pressure within the pressure chamber: the internal brake of theanchor is urged radially inward; the external brake of the anchor isurged radially outward; the internal brake of the die is urged radiallyoutward; and the external brake of the die is urged radially inward; andat a second pressure within the pressure chamber: the internal brake ofthe anchor is urged radially outward; the external brake of the anchoris urged radially inward; the internal brake of the die is urgedradially inward; and the external brake of the die is urged radiallyoutward.
 48. The apparatus of claim 47 wherein the first pressure issubstantially greater than the second pressure.
 49. The apparatus ofclaim 46 wherein the one or more pressure sensing elements comprisesurfaces of each of the internal and external brakes of each of theanchor and the die that are exposed to the hydraulic pressure of thepressure chamber.
 50. The apparatus of claim 42 further comprising ahydraulic system coupled to the anchor and configured to selectivelypressurize the pressure chamber.
 51. The apparatus of claim 50 whereinthe hydraulic system is remotely operable.
 52. The apparatus of claim 50wherein the hydraulic system includes a reservoir and a pump fluidiclycoupling the reservoir and the pressure chamber.